Stellar 6620 User Manual

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Page 1

OWNER’S MANUAL

4387

6620

Safety, Installation, Maintenance, and Operation

6620 Telescopic Crane

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Manual Part No. 31708 Last Revision: 10/31/07

Page 2

6620 Manual Revisions

Date of Revision

September 1, 2005

September 19, 2005

September 9, 2006

November 7, 2006

March 1, 2007

April 12, 2007

Section Revised

Chapter 7: Assembly Drawings

Chapter 7: Assembly Drawings Chapter 8: Hydraulics-Electrical

Chapter 8: Hydraulics-Electrical

Chapter 5: Decals Chapter 7: Assembly Drawings

Description of Revision

Updated Main Boom and Extension Boom drawings to reflect engineering changes.

Updated Cable and Hook assembly drawings to reflect engineering changes.

Updated Base assembly drawings and Hydraulic schematics to reflect engineering changes

Replaced Control Kit 18932 with Control Kit 10701

Updated Decal Kit. Updated assembly drawing for the extension cylinder per engineering changes.

Page 3

Table of Contents i

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Crane Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Unit Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

6 Function Hetronic Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wire Rope Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Torque Data Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Quarterly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Inspection Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Chapter 4 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Capacity Chart - Decal PN 11992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Decal Kit Placement - PN 11993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Chapter 6 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Stability Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Stability Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Chapter 7 - Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Base Assembly - PN 17375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Mast Assembly - PN 17376 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Main Boom - PN 17377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Extension Boom Assembly - PN 17378 . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Extension Boom Assembly (Flip Sheave) - PN 25428 . . . . . . . . . . . . . . . .39

Main Cylinder Assembly - PN 24281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Extension Cylinder Assembly - PN 37017 . . . . . . . . . . . . . . . . . . . . . . . . . .41

Cable & Hook Assembly - PN 38181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Wire Rope/Sheave Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Chapter 8 - Hydraulics - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Control Kit - PN 10701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Control Kit (Power House 24) - PN 38989 . . . . . . . . . . . . . . . . . . . . . . . . . .46

Hydraulic Kit - PN 13042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Valve Bank - PN 24685 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6 Function Hetronic Radio Remote Troubleshooting . . . . . . . . . . . . . . . .55

Transmitter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Receiver Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4 & 7 Function Hetronic Radio Remote Troubleshooting . . . . . . . . . . . .57

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

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ii 6620 Owner’s Manual

Introduction

Stellar Cranes are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these cranes will operate at peak performance for many years.

To promote this longevity, carefully study the information contained in this manual before putting the equipment into service. Though it is not intended to be a training manual for beginners, this manual should provide solid guidelines for the safe and proper usage of the crane.

Once you feel comfortable with the material contained in this manual, strive to exercise your knowledge as you safely operate and maintain the crane. This process is vital to the proper use of the unit.

A few notes on this manual:

A copy of this manual is provided with every crane and shall remain with the crane at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations.

Please be aware that some sections of this manual contain information pertaining to

Stellar manufactured cranes in general and may or may not apply to your specific model.

This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any time, any or all of the items, components, and parts deemed necessary for product improvement or commercial/production purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual.

In closing:

If more information is required or technical assistance is needed, or if you feel that any part of this manual is unclear or incorrect, please contact the Stellar Customer Service Department by phone at 800-321-3741 or email at service@stellarindustries.com.

ATTENTION

Failure to adhere to the

instructions could result in

property damage or even serious

bodily injury to the operator or

others close to the crane.

For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at

800-321-3741

Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST

Or email at the following addresses:

Technical Questions, and Information service@stellarindustries.com

Order Parts parts@stellarindustries.com

Warranty Information warranty@stellarindustries.com

Page 5

Chapter 1 - Safety

Safety 1

Please Read the Following Carefully! This portion of the manual contains information regarding all Stellar manufactured cranes. Some items contained within this chapter may not apply to your specific equipment.

Safety should be the number one thought on every operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. The following information should be read and understood completely by everyone working with or near the crane before putting the unit into operation.

Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the crane because of non-fulfillment from the operator’s side of current rules, laws, and regulations.

GENERAL

It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator with properly maintained equipment.

Do not wear rings, wristwatch, jewelry, loosefitting or hanging clothing such as ties, torn garments, scarves, unbuttoned jackets or unzipped overalls, which could get caught up in the moving parts of the crane.

Keep a first-aid box and a fire extinguisher readily available on the truck. Regularly check to make sure the fire extinguisher is fully charged and the first-aid kit is stocked.

Do not use controls and hoses as handholds. These parts move and cannot provide stable support.

Never allow anyone to ride the crane hook or load.

MAINTENANCE SAFETY

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without explicit approval from Stellar Industries.

Do not perform any maintenance or repair work on the crane unless authorized and trained to do so.

Trainees or untrained persons shall be under the direct supervision of qualified persons.

Do not operate equipment under the adverse influence of alcohol, drugs, or medication.

PERSONAL SAFETY

Keep clear of all moving parts.

Always wear the prescribed personal safety devices.

Always wear approved accident-prevention clothing such as: protective helmets, anti-slip shoes with steel toes, protective gloves, antinoise headphones, protective glasses, and reflective jackets with breathing apparatus. Consult your employer regarding current safety regulations and accident-prevention equipment.

Release system pressure before attempting to make any adjustments or repairs.

Do not attempt service or repair when the PTO is engaged.

Failure to correctly plumb and wire the crane can cause a malfunction and damage to the crane and/or operator.

Decals are considered safety equipment. They must be maintained, as would other safety devices. Do not remove any Decals. Replace any Decals that are missing, damaged, or not legible. The safety instruction plates, notices, load charts and any other sticker applied to the crane or service body must be kept legible and in good condition. If necessary, replace them.

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2 6620 Owner’s Manual

STABILITY

Know the crane components and their capabilities and limitations. Overloading the crane may result in serious injury to self and others, and damage to the equipment and immediate surroundings.

Never exceed manufacturer’s load ratings. These ratings are based on the machine’s hydraulic, mechanical, and structural design rather than stability.

The supporting surface under the service truck must be able to support the weight of the machine and its load. Use outrigger pads if necessary.

Park the vehicle on level ground and extend the outriggers fully out and then down.

Keep feet and legs clear when lowering outrigger jacks.

Never operate the crane without making sure the outriggers are positioned on stable, flat ground.

Set the parking brake and disengage the drive axle before attempting a lift.

LOAD SAFETY

Operate the crane in compliance with the load capacity chart at all times. Know the weight of the load being lifted. Do not rely on the overload device to determine maximum rated loads. If the crane is picking more than

the maximum rated load, the overload

protection device may be malfunctioning. Discontinue use immediately and contact Stellar Customer Service for support.

Never use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing. This would negate the safety feature.

Do not apply side loads to the booms.

Do not walk under suspended loads.

Do not position any load over a person nor should any person be permitted to place him or herself under a load.

Do not use the boom or the winch to drag a load.

Do not use the crane boom to push downward onto anything.

ELECTROCUTION

Allow extra space for swaying power lines in windy conditions.

Keep a minimum of ten feet between any portion of the crane and an electrical line. Add an additional 12" for every additional 30,000 Volts or less.

Remember - Death or serious injury can occur when working near power lines or during electrical storms.

Use a signal person when operating near electrical sources.

ENVIRONMENT

Do not operate the crane during electrical storms.

In extreme cold, allow adequate time to warm the truck before engaging the PTO. Do not rev the truck engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding operating the vehicle in such adverse conditions.

In dusty work areas, every effort must be taken to keep dust and sand out of the moving parts of the machinery.

In high humidity work areas, keep parts as dry as possible and well lubricated.

Do not leave a crane load suspended or unattended.

Page 7

Safety 3

Crane Controls

1. Be familiar with the sequence and operation of the crane controls.

2. Each individual crane function should have control function decals. Replace them immediately if they are missing or illegible.

3. Keep hands, feet, and control levers free from mud, grease, and oil.

4. Be familiar with the remote control and how it operates before attempting to lift a load.

5. Be prepared before beginning operation of the crane:

• All protective guards must be in place.

• Be aware of the surroundings: low branches, power lines, unstable ground.

• Be sure all safety devices provided are in place and in good operating condition.

• Be prepared for all situations. Keep fire extinguisher and first aid kit near.

• Be sure all regular maintenance has been performed.

• Visually inspect all aspects of the crane for physical damage.

• Check for fluid leaks.

• Make sure the outriggers are down and stable.

Be familiar with your remote control and

how it works before operating the crane.

ATTENTION

Stellar Industries, Inc. is not liable

for accidents incurred by the

crane because of the operator’s

non-fulfillment of current rules,

laws and regulations.

Page 8

4 6620 Owner’s Manual

Page 9

Chapter 2 - Operation

Operation 5

This chapter contains information regarding the operation of Stellar manufactured telescopic cranes. Please study the following pages to ensure your familiarity with the operation process. This understanding is vital to the safe and efficient operation of the crane.

Job-Site Set-Up

Thoroughly plan the lift before positioning the vehicle. Consider the following:

1. The vehicle should be positioned in an area free from overhead obstructions to eliminate the need for repositioning.

2. Position the vehicle so that it is impossible for any portion of the equipment to come within the minimum required safe distance of any power line. Maintain a clearance of at least 10 feet between any part of the crane, load line, or load, and any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. Remember to allow for winds that cause power lines to sway. It is recommended that a signal person be used when the vehicle is set-up near power lines.

3. The vehicle should also be positioned on a firm and level surface that will provide adequate support for the outrigger loading. Use extreme caution when setting up near overhanging banks or excavations.

4. The parking brake must be set on the vehicle and the drive axle disengaged before performing a crane operation.

5. The outriggers must be extended to stabilize the truck before beginning operation.

Unit Operation Overview

1. Engage the PTO

2. Turn on Power to Crane

3. Position Outriggers

4. Operate Crane

5. Store Outriggers

6. Turn Off Power to Crane

7. Disengage the PTO

1. Engage the PTO

A. Engage the parking

brake.

B. Place the

transmission in the Neutral position.

C. Make certain the

PTO switch is in the

‘off’ position. D. Start the vehicle engine. E. Depress the clutch on manual

transmission vehicles.

F. Engage the PTO switch for cable and air

type shifters. Turn on the dash switch for electrical operated style. Consult vehicle owner’s manual for location and operation of OEM style in-dash PTO switch.

G. Slowly release the clutch on a manual

transmission vehicle.

H. Allow a few moments to warm the

hydraulic system oil. In cold weather, it is especially important to let the system run for a few minutes before operating.

2. Turn on Power to Crane

Activate power to the crane and outriggers. The power switch is located on the control panel in the vehicle cab.

3. Position Outriggers

Once the PTO is engaged, extend the outriggers using the control levers or switches marked ‘outrigger’. These may be located on the crane base or in the compartment under the crane.

PTO Switch

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6 6620 Owner’s Manual

6 Function Hetronic Remote

4.Operate Crane

A. Turn on necessary power to the crane. B. Activate toggle switch for desired crane

function.

D. Activate the variable speed trigger to

control the desired function.

E. When operation is complete, store

remote handle in a safe, dry location.

5. Store Outriggers

Retract outriggers using the control levers or switches marked ‘outrigger’.

6. Turn Off Power to Crane

Deactivate power to crane and outriggers.

7. Disengage the PTO

A. On manual transmission vehicles,

depress the clutch pedal completely. B. Disengage the PTO switch. C. If vehicle is a manual transmission,

release the clutch pedal gradually.

NOTE: The radio control is an electri-

cal device. Please handle with care!

Variable Speed Trigger on remote.

The crane should not function until the trigger has been

activated. The speed of the crane will vary in direct

correlation with how much or how little the trigger is engaged.

Page 11

Operation 7

MAIN

XTENSION

XTEND

RETRACT

MAIN

OWN

EXTENSION

OWN

ROT

PULL

PUSH

ONTROL

LOW

WINCH

Manual Operation

If the remote control malfunctions, follow these steps to operate the crane manually:

1. Activate Flow Control. Turn the override screw on flow control counter-clockwise. Full adjustment is between three and five turns. Operate Solenoids. Slide the knurled sleeve

2. out and then push or pull to operate, as shown below. Be sure the sleeve is in the center, locked, position before returning to remote operation.

3. Deactivate flow control. Turn the override screw clockwise until stopped. Full adjustment is between 3 and 5 turns.

4. Have unit serviced immediately to restore remote control functionality.

Crane Precautions

1. Movement of the control levers should be slow and smooth to meter oil flow for safe operation. Avoid jerky and sudden movements.

2. The crane controls should be clearly marked with decals. If these are missing or illegible,replace immediately. (See Chapter 5: Decals)

3. Lift load slightly off the ground to check the safety of the cargo. Do not use stability to determine the safety. Consult the capacity charts and strictly adhere to them.

4. Be constantly aware of the boom position when operating the controls.

5. The boom tip should be centered directly over the load before making the lift to avoid swinging.

6. Do not drag loads with the crane.

7. Do not attempt to lift fixed loads.

8. Do not load boom in a sideways direction.

9. Know the weight of the rigging and load to avoid overloading the crane.

10. Do not extend or rotate a load over anyone.

11. Wear protective gear such as hard hat, safety glasses, steel-toed boots, and gloves.

Hook Precautions

1. Hooks are designed and manufactured to

lift specific loads. The specified rated load of a hook applies to loads held uniformly in

Manual Override Pull Function

The knurled sleeve is pulled all the way out together with the knob to manually override the pull solenoid function.

direct tension and does not take into account shock loads, hook tip loading, side loading, bending, torsional, or related loads.

2. Do not attempt to lift a load that is larger

than the load rating of the hook.

3. Never use a hook’s yield point as an

indicator of its capacity.

4. Do not use a hook to lift personnel.

5. Know the rated load of the hook in use.

6. Never weld attachments to a finished hook

Manual Override Push Function

The knurled sleeve should first be pulled to unlatch the ball latching mechanism and then, while holding the sleeve back, the override knob should be pushed all the way in to override the push solenoid.

in field applications. This will alter and destroy the design properties of the hook material.

7. Keep fingers, hands, body, and loose

clothing from between the hook and the load.

8. Avoid shock loading.

9. Inspect the hook regularly for excessive

wear and maintain it in safe operating condition.

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8 6620 Owner’s Manual

Operator Information

OPERATOR REQUIREMENTS

1. Operation is limited to the following people:

A. Designated individual. B. Trainees under direct supervision

of the designated individual. C. Test or maintenance individual. D. Crane Inspector.

2. Operators must meet the following physical qualifications:

A. Vision of at least 20/30 Snellen in

one eye and 20/50 in the other, with or without corrective lenses.

B. Ability to distinguish colors if color

differentiation is required.

C. Adequate hearing, with or

without a hearing aid.

D. No physical or emotional defects

that may create a hazard to the operator or others.

E. Normal depth perception and

coordination.

3. In addition to the physical qualifications,

Operators must:

A. Demonstrate the ability to

understand all decals, the owner’s manual, and any other information required for safe operation of the crane.

B. Be able to demonstrate the ability

to safely control the crane. C. Know all safety regulations. D. Be responsible for maintenance

requirements.

E. Understand and be fully capable

of implementing all emergency

procedures. F. Understand the operating

procedures as outlined by this manual, ANSI B30.5, and Federal/State Laws.

OPERATOR CONDUCT

1. Operators will not engage in any operation that would cause them to divert attention away from the operation of the crane.

2. Operators are responsible for all operations under their direct control.

3. Operators will not leave a suspended load unattended.

4. Operators will be familiar with the equipment and the maintenance required for proper care.

HANDLING THE LOAD

1. Size of the load:

A. Do not load the crane beyond

the rated capacity.

B. It is the responsibility of the

operator to know the weight of the handled load.

2. Attaching the load:

A. Attach the load to the hook by

means of slings or other approved devices.

B. Do not wrap the hoist rope

around the load.

3. Moving the load:

A. Make certain that the crane is

level and properly blocked.

B. Ensure that the load is secure and

balanced within the sling before moving it.

C. Be sure that the crane is stable

before moving the load. Use stabilizer pads to ensure the

proper distribution of weight. D. Do not drag the load sideways. E. Make sure the hook is brought

over the load to minimize swinging.

F. No suspended load should pass

over a person.

G. Avoid sudden starts and stops

when moving a load.

Page 13

Chapter 3 - Maintenance

Maintenance 9

WARNING - Read the Following before performing any maintenance on the

crane.

1. Only authorized service personnel are to perform maintenance on the crane.

2. Disengage the PTO before any service or repair is performed.

3. Do not disconnect hydraulic hoses while there is still pressure in those components.

4. Before disconnecting hydraulic

components, place the boom on the ground or have it supported, shut off the engine, release any air pressure on the hydraulic reservoir, and move pedals and control levers repeatedly through their operating positions to relieve all pressures.

5. Keep the crane and service body clean and free from grease build-up, oil and dirt to prevent slippery conditions.

6. Perform all safety and maintenance checks before each period of use.

7. Replace parts with Stellar Industries, Inc. approved parts only.

8. Immediately repair or have repaired any components found to be inadequate.

Maintenance Procedures

1. Position the crane where it will be out of the way of other operations or vehicles in the area.

2. Be sure boom is lowered to the ground or otherwise secured from dropping.

3. Place all controls in the off position and secure operating features from inadvertent motion.

4. Disconnect power source.

5. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.

6. Label or tag parts when disassembling.

Daily Inspection

Daily Inspection should occur each day before the crane is put into use. Each day, inspect the crane for all of the following:

1. Hydraulic oil level.

2. Loose parts or damage to structures or weld.

3. Cylinder movement due to leakage.

4. Hoses and gearboxes for evidence of oil leaks.

5. Controls, including hand throttle for malfunction or adjustment.

6. Truck hand brake operation.

7. All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper installation.

8. All safety covers for proper installation.

9. Cylinder holding valves for proper operation.

10. Wire rope for broken wires, extensive

wear, distortion, and heat damage.

Periodic Inspection

Periodic Inspection should occur while the crane is in use. For the duration of the usage, inspect the crane for all of the following:

1. Loose bolts and fasteners.

2. All pins, bearings, shafts, and gears for

wear, cracks, or distortion to include all pivots, outriggers, sheave pins, and bearings.

3. Hydraulic systems for proper operating

pressure.

4. Main frame mount bolts.

5. Cylinders for:

A. Damaged rods. B. Dented barrels. C. Drift from oil leaking internally. D. Leaks at rod seals or holding valves.

6. PTO drive line system for proper

alignment, lubrication, and tightness.

7. Hydraulic hose and tubing for evidence of

damage such as blistering, crushing, or abrasion.

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10 6620 Owner’s Manual

Weekly Inspection

Weekly Inspection should occur at the beginning of every work week. Each week, inspect the crane for all of the following:

1. Lubrication of points required by lubrication chart located in this chapter.

2. Proper operation of load hook safety latch.

3. Presence of this owner’s manual.

Monthly Inspection

Monthly Inspection should occur at the beginning of every work month. Each month, inspect the crane for all of the following:

1. Frame bolt tightness - turn barrel nuts and mounting bolts during the first month of operation on new machines and then quarterly thereafter.

2. Cylinders and valves for leaks.

3. Lubrication.

4. Load hook for cracks or having more than 15 percent normal throat opening or 10 degrees twist.

5. Structural members for bends, cracks, or broken members.

6. All welds for breaks and cracks.

7. All pins and keepers for proper installation.

8. All control, safety, and capacity placards for readability and secure attachment.

9. Inspect all electrical wires and connections for worn, cut, or deteriorated insulation and bare wire. Replace or repair wires as required.

10. Tightness of all boom wear, pad-retaining

bolts.

Service

The following general suggestions should be helpful in analyzing and servicing your crane. Using the following systematic approach should be helpful in finding and fixing problems:

1. Determine the problem.

2. List and record possible causes.

3. Devise checks.

4. Conduct checks in a logical order to determine the cause.

5. Consider the remaining service life of components against the cost of parts and labor necessary to replace them.

6. Make the necessary repair.

7. Recheck to ensure that nothing has been overlooked.

8. Functionally test the new part in its system.

Inspection Checklist

For a more detailed outline of scheduled inspection points, refer to the Stellar Inspection Checklist at the end of this chapter. This list is an excellent guide for the inspection tasks that will help maintain the quality of your Stellar product. Feel free to photocopy the checklist as needed.

ATTENTION

Every six (6) months,

Stellar Industries recommends the first

filter change to occur after the first 250

hours of service.* The second, and

every subsequent change, should

occur after every 1,000 hours of

service. By following these guidelines,

the hydraulic oil should last up to

6,500 hours.

*Note: These recommendations are based on normal

working parameters. If operating in less than favorable

conditions (excessive dust, moisture, etc.), be sure to check

the filter gauge often for filter change notice.

remove the hydraulic

pump from the PTO and

lubricate the splines using Chelsea Lubricant #379831 or Stellar PN 20885. Failure

to lubricate shaft splines will

cause damage to the PTO

and Hydraulic pump.

Page 15

Lubrication Recommendations

Component Location Recommendation

Engine Crankcase Apply Manufacturer’s

Recommendations

Maintenance 11

Hydraulic System Below –5*F

-5*F to 90*F Above 90*F

Open Gears Hand Precision XL3 Moly EP 2 (NLGI 2 grease

Bearings, grease (including turntable bearing inner race)

Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00)

Planetary Gearbox (including winch)

Reservoir

Petro-Canada Arctic MV 15 (ISO 22) Petro-Canada HYDREX 32 (ISO 32) Petro-Canada HYDREX 46 (ISO 46)

with moly)

Gun Precision XL EP 2 (NLGI 2)

Gearbox Traxon Synthetic 75W-90 (API GL-5)

Wear Pad Lubrication Spray Gearshield NC

Compressor Fluids

Reciprocating Single Stage Reciprocating Double Stage

Screw

-15˚F to 86˚F

-23˚F to 100˚F 32˚F to 113˚F

Crankcase Crankcase

Crankcase

Compro 100 (ISO 100) Compro 100 (ISO 100)

Compro XL-S 32 (ISO 32) Compro XL-S 46 (ISO46) Compro XL-S 68 (ISO68)

Greasing the Crane

Lubricate all grease gun points with

Extreme Pressure Grease - Stellar P/N: 22059.

Page 16

12 6620 Owner’s Manual

Wire Rope Maintenance

Wire Rope Inspection Points

While inspection of the entire rope is required, attention should be directed to these critical points:

1. Pick-up Points for signs of wear due to stress from repeated lifts.

2. End Attachments for corrosion and broken wires at both ends of the rope. Drums for signs of corrugation and wear

3. that may lead to wire damage. Sheaves to ensure that each sheave has

4. the proper groove size and contour.

5. Abuse Points for heavy amounts of scuffing and scraping.

It is important to perform detailed inspections of all ropes associated with the crane. These inspections can be divided into two types:

1. Frequent Inspection

A. All running ropes should be inspected

once each working day. These visual observations will be concerned with discovering damage that may be an immediate hazard. The following concerns should be addressed:

1. Distortion of the rope.

2. General corrosion.

3. Broken or cut strands.

B. Use caution while inspecting sections of

rapid deterioration.

C. Use caution while inspecting boom

hoist ropes. Proper inspection is critical but difficult.

Periodic Inspection

A. Inspection frequency will be

determined by a qualified person and will be based on such factors as expected rope life, environment conditions, capacity of typical lifts, rates of usage, and exposure to shock loads. Periodic inspection needs to be performed at least annually.

B. Periodic inspections will be performed

by a qualified individual and will cover the entire length of the rope. Only the

surface wires of the rope need to be inspected. This inspection will be concerned with discovering damage that may be an immediate hazard. The following concerns should be addressed:

1. Distortion of the rope.

2. General corrosion.

3. Broken or cut strands.

4. Reduction of rope diameter.

5. Corroded or broken wires at end connections.

6. Corroded, cracked, bent, worn, or improperly applied end connections.

C. Use caution when inspecting the

following:

1. Sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited.

2. Sections of the rope at or near ends with corroded or broken wires.

Wire Rope Replacement

Rope replacement guidelines are as follows:

1. Broken wires, including standing ropes with more than two broken wires in one lay or more than one broken wire at an end connection.

2. Wear of one-third the original diameter of the outside wires.

3. Distortion of the rope structure.

4. Evidence of heat damage.

5. Reductions from nominal diameters of more than 1/64 in. (0.4 mm) for diameters from 5/16 in.(19.0 mm) and 1/32 in. (0.8 mm) for diameters from 3/8 in. (9.5 mm) to and including 1/2 in. (13.0 mm).

Wire Rope Maintenance

Proper maintenance is key in ensuring a long lasting rope. These three tips will help:

1. Store the rope to prevent damage.

2. Avoid objects that may scrape, bend, or crush the wires of the rope.

3. Always keep the rope well-lubricated.

Page 17

Holding Valve Inspection Procedure

The cylinders are equipped with holding valves that prevent sudden movement of the cylinder rods in the event of a hydraulic hose or hydraulic component failure. The valve is checked in the following manner:

1. Identify the cylinder in question.

2. Identify the holding valves and the cylinder direction in question.

a. Cylinder Extend. b. Cylinder Retract.

3. Place the machine so that the cylinder will be located in the appropriate testing

position.

4. Pick the load (Do not exceed capacity, rated or stability).

5. Disengage hydraulics.

6. Operate crane functions.

A. If the cylinder creeps (lowering the

load), replace the holding valve.

B. If the cylinder does not creep (load

stays suspended), the valve is operational.

Maintenance 13

Torque Data Chart

Grade 5

Plated

Size

(DIA-TPI)

5/16-18

3/8-16

7/16-14

1/2-13

9/16-12

5/8-11 3/4-10

7/8-9

1-8 1 1/8-7 1 1/4-7 1 3/8-6 1 1/2-6

Bolt DIA

(Inches)

0.3125

0.3750

0.4375

0.5000

0.5625

0.6250

0.7500

0.8750

1.000

1.1250

1.2500

1.3750

1.500

Plain

(Ft-Lb)

17 31 49

75 110 150 265 395 590 795

1120 1470 1950

(Ft-Lb)

13 23 37 57

82 115 200 295 445 595 840 110

1460

When using the torque data in the charts above, the following rules should be observed.

Grade 8

Plain

(Ft-Lb)

25 44

70 105 155 220 375 605 910

1290 1815 2380 3160

Plated

(Ft-Lb)

18 33 52

80 115 160 280 455 680 965

1360 1780 2370

Grade 9

Plated

(Ft-Lb)

22 39 63

96 139 192 340 549 823

1167 1646 2158 2865

Gear-Bearing Bolt Maintenance

Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as when the bolt was new thus giving indeterminate damp loads after torquing.

Warning!

Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing serious injury or even death.

1. Bolt manufacturer’s particular specifications should be consulted when provided.

2. Flat washers of equal strength must be used.

3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.

4. Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, colloidal copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect the torque values listed above.

5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.

Page 18

14 6620 Owner’s Manual

Inspection Checklist

Use of this checklist is subject to terms of the Stellar Warranty information. Additional copies of this checklist can be obtained by contacting Stellar Customer Service at (800) 321-3741.

Owner/Company: Contact Person: Crane Make/Model: Crane Serial:

Type of Inspection (check one)

Daily (if deficiency found)

Monthly

Date Inspected: Hour Meter Reading: Inspected by: ( Signature of Inspector:

print)

Quarterly

Annual

Type of Inspection Information

Daily and monthly inspections are to be performed by a “designated” person, who has been selected by the employer or the employer’s representative as being competent to perform specific duties.

Quarterly and annual inspections are to be performed by a “qualified” person who, by possession of a recognized degree in an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work.

One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly.

Consult the Stellar Owner’s Manual for additional inspection items.

Before inspecting and operating the crane, make certain that t he crane is set up away from power lines and leveled with outriggers fully extended.

Daily (D): Before each day of operation, those items with a (D) must be inspected. This inspection need not be recorded unless a deficiency is found.

Monthly (M): Monthly inspections or 100 hours of normal operation (which ever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be recorded.

Quarterly (Q): Every three months or 300 hours of normal operation (which ever comes first) includes all daily and monthly inspection items plus items designated with an (M). This inspection must be recorded.

Annual (A): Each year or 1200 hours of normal operation (which ever comes first) includes all items on this form which encompasses daily, monthly, and quarterly inspections plus those items designated by (A). this inspection must be recorded.

Page 19

Daily Inspection

Maintenance 15

Frequency

Key

Decals

Controls

Station

Hydsystem

Hook

Rope

Pins

General

Operation

Remote Ctrls

Electrical

Inspection Description

All load charts, safety & warning Decals, & control Decals are present and legible. Check all safety devices for proper operation.

Control mechanisms for proper operation of all functions, leaks, & cracks.

Hydraulic system (hoses, tubes, & fittings) for leakage & proper oil level.

Presence & proper operation of hook safety latches.

Proper reeving of wire rope on sheaves & winch drum.

Proper engagement of all connecting pins & pin retaining devices.

Overall observation of crane for damage or missing parts, cracked welds & presence of safety covers. During operation, observe crane for abnormal performance, unusual wear. If observed, discontinue use & determine cause & severity of hazard. Operate remote control devices to check for proper operation.

Operate all lights, alarms, etc. to check for proper operation.

Status

Anti 2-Blocking

Operation Aid

Operate anti 2-blocking device to check for proper operation.

Check presence of boom angle indicator.

Check overload device for proper operation.

Page 20

16 6620 Owner’s Manual

Monthly Inspection

Frequency

Key

Daily

Cylinders

Valves

General

Electrical

Structure

Welds

Pins

Hardware

Wear Pads

Inspection Description

All Daily Inspections.

Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod & case. Holding valves for proper operation.

Control valve for leaks at fittings & between sections.

Control valve linkages for wear, smoothness of operation & tightness of fasteners. Relief valve for proper pressure settings. Bent, broken or significantly rusted/corroded parts.

Electrical systems for presence of dirt, moisture & frayed wires.

All structural members for damage.

All welds for breaks & cracks.

All pins for proper installation & condition.

All bolts, fasteners & retaining rings for tightness, wear & corrosion.

Condition of wear pads.

Status

Pump & Motor

PTO

Hyd Fluid

Hyd Lines

Hook

Rope

Manual

Chassis

Station

Hydraulic pumps & motors for leakage at fittings, seals & between sections. Check tightness of mounting bolts. Transmission/PTO for leakage, abnormal vibration & noise, alignment & mounting bolt torque. Quality of hydraulic fluid and for presence of water.

Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage, & secured properly. Load hook for abnormal throat distance, twist, wear, & cracks.

Condition of load line.

Presence of operator's manuals with the unit.

Tire wear and air pressure.

Working backup alarm.

Fire extinguisher at cab or machinery housing.

Page 21

Quarterly Inspection

Maintenance 17

Frequency

Key

Daily

Monthly

Rotation Sys

Hardware

Structure

Inspection Description

All daily inspections.

All monthly inspections.

Rotation bearing for proper torque of all mounting bolts.

Base mounting bolts for proper torque.

All structural members for deformation, cracks, & corrosion.

Base

Outrigger beams & legs

Mast

Inner boom

Outer boom

Extension(s)

Jib boom

Status

Hardware

Jib extension(s)

Other

Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks, corrosion, & distortion. Inner boom pivot pin(s) & retainer(s)

Outer boom pivot pin(s) & retainer(s)

Inner boom cylinder pin(s) & retainer(s)

Outer boom cylinder pin(s) & retainer(s)

Extension cylinder pin(s) & retainer(s)

Jib boom pin(s) & retainer(s)

Jib cylinder pin(s) & retainer(s)

Jib extension cylinder pin(s) & retainer(s)

Boom tip attachments

Other

Page 22

18 6620 Owner’s Manual

Quarterly Inspection Continued...

Frequency

Key

Hyd Lines

Pumps&Motors

Valves

Inspection Description

Hoses, fittings, & tubing for proper routing, leakage, blistering, deformation, & excessive abrasion. Pressure line(s) from pump to control valve

Return line(s) from control valve to reservoir

Suction line(s) from reservoir to pump

Pressure line(s) from control valve to each function

Load holding valve pipe(s) and hose(s)

Other

Pumps and motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating and excess pressure. Winch motor(s)

Rotation motor(s)

Other

Hydraulic valves for cracks, spool return to neutral, sticking spools, relief valve failure. Main control valve

Status

Cylinders

Winch

Hyd Filter

Load holding valve(s)

Outrigger or auxiliary control valve(s)

Other

Hydraulic cylinders for drifting & leakage. Rods for nicks, scores, & dents. Castor damage. Case & rod ends for damage & abnormal wear. Outrigger cylinder(s)

Inner boom cylinder(s)

Outer boom cylinder(s)

Extension cylinder(s)

Rotation cylinder(s)

Jib lift cylinder(s)

Jib extension cylinder(s)

Other

Winch, sheaves, & drums for damage, abnormal wear, abrasion, & other irregularities. Hydraulic filters for replacement per maintenance schedule.

Page 23

Annual Inspection

Maintenance 19

Frequency

Key

Daily

Monthly

Quarterly

Hyd System

Controls

Valves

Rotation Sys

Lubrication

Hardware

Wear Pads

Loadline

Inspection Description

All daily inspection items.

All monthly inspection items.

All quarterly inspection items.

Hydraulic fluid change per maintenance schedule.

Control valve calibration for correct pressures & relief valve settings.

Safety valve calibration for correct pressures & relief valve settings

Valves for failure to maintain correct settings.

Rotation drive system for proper backlash clearance & abnormal wear, deformation, & cracks. Gear oil change in rotation drive system per maintenance schedule.

Check tightness of all fasteners and bolts.

Wear pads for excessive wear.

Loadline for proper attachment to drum.

Status

Historic Data

Monthly inspection records.

Maintenance records.

Repair and modification records.

Page 24

20 6620 Owner’s Manual

Inspection Notes

Page 25

Chapter 4 - Specifications

Model 6620 Crane

SPECIFICATION SHEET

Crane Rating: 38,000 ft-lbs (5.25 ton-meters)

Standard Boom Length: 10’ 9” (3.28 m) from CL of Crane

Boom Extension: 1st stage: Hydraulic 60” (152.4 cm)

2nd stage: Hydraulic 60” (152.4 cm)

Maximum Horizontal Reach: 20’ 9” (6.32 m) from CL of Crane

Maximum Vertical Lift: 22’ (6.71 m) (from crane base)

Boom Elevation: -5 to +80 degrees

Specifications 21

Stowed Height: 32.5” (82.6 cm) (crane only)

Mounting Space Required: 20” x 21” (50.8 x 53.3 cm)

Approximate Shipping Weight: 1625 lbs (735 kg)

Controls: Radio control standard

for all functions.

Winch Specifications

Rope Diameter: 5/16" (.794 cm) Line pull speed: 60 ft/min (18.29 m/min) Max. single part line: 3000 lbs (1360 kg) Max. double part line: 6000 lbs (2720 kg)

Rotation: 400 degree power (worm gear)

Lifting Capacities: 3525 lbs @ 10’ 9” (1600 kg @ 3.28 m)

1825 lbs @ 20’ 9” (830 kg @ 6.32 m)

Power Supply Required: PTO & Pump

(8.0 gpm @ 2850 psi) (30.31 lpm @ 197 bars)

*Subject to change without notification

Page 26

22 6620 Owner’s Manual

Reach in Feet/Meters Capacity in Pounds/Kilograms

Weight of load handling devices are part of the load lifted and must be deducted from the capacity.

6620

PN 11992

Maximum 1 - part line capacity is 3000lbs (1360kg). For greater loads, use 2 - part line.

3525lbs

1600kg

2400lbs

1090kg

1825lbs

830kg

3575lbs

1620kg

2450lbs

1110kg

3900lbs

1770kg

1875lbs

850kg

4600lbs

2085kg

2700lbs

1225kg

2050lbs

930kg

5550lbs

2515kg

3075lbs

1395kg

2300lbs

040kg

6000lbs

2720kg

6000lbs

2720kg

6000lbs

2720kg

6000lbs

2720kg

3775lbs

1710kg

5775lbs

620kg

4500lbs

2040kg

2850lbs

290kg

Capacity Chart - Decal PN 11992

Page 27

Chapter 5 - Decals

Decals of Note

Foot Crushing Hazard Decal

Location: On each outrigger leg. Function: To inform the operator and other

personnel in the work area of the hazard associated with the operation of the outriggers, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C4795

Decals 23

Instructional Decal

Location: At Stow Hook area Function: To caution the operator not to use the

stow hook for any lifting applications. PN: 24712

Moving Outrigger Hazard Decal

Location: On each outrigger Function: To inform the operator of the hazard

associated with outrigger operation, the possible consequences should the hazard occur, and how

to avoid the hazard

. PN: C5918

Page 28

24 6620 Owner’s Manual

Electrocution Hazard Decal

Location: Each side of truck body, Front & Rear

Bumper Function: To inform the operator and other personnel in the work area of the hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur and how to avoid the hazard. PN: C4545

Page 29

Decals 25

Two Block Hazard Decal

Location: At Boom Tip Function: To inform the operator of the hazard associated with bringing the sheave(s) into contact with the hook, snatch block or load, the possible consequences should the hazard occur and how to avoid the hazard. PN: 12300

Instructional Decal

Location: At Overload Switch Function: To inform the operator that tampering with the overload device may cause a unit failure. PN: 28256

Page 30

26 6620 Owner’s Manual

Free Falling Manual Boom Decal

Location: Inside Crane Compartment, on

Compartment Door Function: To inform the operator of the hazard associated with free falling manual boom extensions, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 12452

Electrocution Hazard Decal

Location: Inside Crane Compartment, on

Compartment Door Function: To inform the operator of the hazard associated with overloading the crane, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C1179

Operation Hazard Decal

Location: Inside Crane Compartment, on

Compartment Door Function: To inform the operator and other personnel in the work area of the hazard associated with improper maintenance and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4190

Operation Hazard Decal

Location: Inside Crane Compartment, on

Compartment Door Function: To inform the operator of the hazard associated with overloading the crane, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4189

Page 31

Decals 27

Moving Boom Hazard Decal

Location:Inside Crane Compartment, on

Compartment Door Function: To inform the operator and other personnel in the work area of the hazard associated with a moving boom, especially while stowing and unfolding the crane, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C4541

Operation Hazard Decal

Location:Inside Crane Compartment, on

Compartment Door Function: To inform the operator of the need for proper training, familiarity with safe operating procedures and, the possible consequences without training. PN: C4540

Hoisting Decal:

Location: Inside Crane Compartment, on

Compartment Door Function: To inform the operator of the hazard associated with lifting personnel with the boom, boom hook, the load or winch loadline, the possible consequences of lifting personnel, and how to avoid the hazard. PN: 12451

Training Decal:

Location:Inside Crane Compartment, on

Compartment Door Function: To inform the operator of the need for proper training, familiarity with safe operating procedures, and the possible consequences of operation without training. PN: C4544

Page 32

28 6620 Owner’s Manual

PN 11993

Decal Kit Placement - PN 11993

Page 33

Installation 29

Chapter 6 - Installation

Notice: Read this Page Before Installation of the Crane

General Installation

This chapter is designed to serve as a general guide for the installation of a Stellar 6620 Telescopic Crane on a Stellar Service Body. Each installation is considered unique so certain portions of this chapter may or may not apply to your direct application. If a question should arise during the installation process, please contact Stellar Customer Service at (800) 321 3741.

This crane is designed for use with a Stellar Service Body installed on a vehicle that meets the minimum chassis requirements of the crane. Check with Stellar Industries before installing this crane on a body other than a Stellar Service Body.

WARNING!

The use of this crane on a body not

capable of handling the loads

imposed on it may result in serious

injury or death.

Notice:

PTO and Pump installation instructions are provided by the corresponding manufacturers. For more information on which PTO and Pump fit your application, please contact your local Stellar Distributor or Stellar Customer Service.

Installation Notice

According to Federal Law (49 cfr part 571), each final-stage manufacturer shall complete the vehicle in such a manner that it conforms to the standards in effect on the date of manufacture of the incomplete vehicle, the date of final completion, or a date between those two dates. This requirement shall, however, be superseded by any conflicting provisions of a standard that applies by its terms to vehicles manufactured in two or more stages.

Therefore, the installer of Stellar cranes and bodies is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations. They are required to certify that the vehicle is in compliance with the Federal Motor Vehicle Safety Standards and other regulations issued under the National Traffic and Motor Vehicle Safety Act.

Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-999), for further information, or visit http://www.gpoaccess.gov/nara/index.html for the full text of Code of Federal Regulations.

Optimal Service Body

for the 6628 Crane:

T1-11 Service Body

Applicable Chassis: 16000 to 19000 GVWR Cab to Axle: 84” (213.36 cm) Body Length Nominal: 133” (337.82 cm) Body Height: 44” (111.76 cm) Body Width: 94” (238.76 cm) Compartment Depth: 22” (55.88 cm) Floor Width: 50” (127 cm) Net Weight: 3220 lbs (1460.37 kg)

Optimal Service Body

for the 6628 Crane:

T2-11 Service Body

Applicable Chassis: 19000 GVWR and up. Cab to Axle: 84” (213.36 cm) Body Length Nominal: 133” (337.82 cm) Body Height: 52” (132.08 cm) Body Width: 94” (238.76 cm) Compartment Depth: 22” (55.88 cm) Floor Width: 50” (127 cm) Net Weight: 3600 lbs (1632.93 kg)

Page 34

30 6620 Owner’s Manual

FRONT

Motor

Hole Mounting Detail

Ø1.063

7.38

14.75

7.38

14.75

Ø6.00

4 Places

65382

ITEM NO. PART NO.

1 5199

QTY.

WASHER 1.00 SAE FLAT YELLOW GR8

CAP SCR 1.00X8X3.00 HHGR8 ZY

DESCRIPTION

Installation Overview

1. Determine that the mounting location for the 6620 crane is at least 18” x 20” (45.7 x 50.8 cm).

2. Use the detail below to drill 1.06” diameter holes into the mounting plate. Run tap on the threads of the base to be sure they are clean.

3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 6620 weighs approximately 1625 lbs (735 kg). degree system. This will allow for easy installation of the crane and permanent connection of all hydraulic and electrical components prior to repositioning into the crane saddle.

4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 6620.

5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.

6. Install a washer on each bolt.

7. Apply Loctite Thread locker #277 to the bolts.

8. Using the lifting device, lower the Stellar 6620 just above the crane compartment and start the bolts. Have someone assist in leveling the crane.

compartment and the boom should be extended back over the rear bumper.

9. Secure the crane using the mounting hardware provided. Note: longer or shorter cap screws may be

required – recommended thread engagement into crane base is 1.75” – use grade 8, zinc plated cap screws only.

10. Torque the cap screws to 680 ft-lbs.

11. Remove supporting crane.

12. 12. Hook-up hydraulics and electrical using the schematics provided in

Electrical. Note: If questions should arise during any portion of this installation, please contact Stellar Customer Service at (800) 321-3741.

Note: cranes are shipped with rotation positioned at 200 degrees of 400

Note: the rotation motor should be to the door side of crane

Chapter 8 - Hydraulics -

The following pages will give a basic overview of the installation process for the Stellar 6620. Please read thru them entirely and obtain a clear understanding of the process before proceeding.

Page 35

Installation 31

Installation Details

1. Determine that the

mounting location for the 6620 crane is at least 18” x 20” (45.7 x 50.8 cm).

2. Use the detail on the

previous page to drill 1.06” diameter holes into the mounting plate. Run tap on the threads of the base to be sure they are clean.

3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar

6620 weighs approximately 1625 lbs (735 kg).

positioned at 200 degrees of 400 degree system.

crane and permanent connection of all hydraulic and electrical components prior to repositioning into the crane saddle.

Note: cranes are shipped with rotation

This will allow for easy installation of the

4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 6620.

5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.

6. Install a washer on each bolt.

7. Apply Loctite Thread locker #277 to the bolts.

The number of bolts used may

vary from model to model.

8. Using the lifting device, lower the Stellar 6620 just

above the crane compartment and start the bolts. Have someone assist in leveling the crane.

rotation motor should be to the door side of crane compartment and the boom should be extended back over the rear bumper.

Note: the

Page 36

32 6620 Owner’s Manual

Installation Details Continued...

9. Secure the crane using the mounting

hardware provided. Note: longer or shorter

cap screws may be required – recommended thread engagement into crane base is 1.75” – use grade 8, zinc plated cap screws only.

10. Torque the cap screws to 680 ft-lbs.

11. Remove supporting crane.

12. Hook-up hydraulics and electrical using the schematics provided in

Hydraulics - Electrical.

Note: If questions should arise during any portion of this installation, please contact Stellar

Customer Service at (800) 321-3741.

Chapter 8 -

Page 37

Installation 33

Stability Procedure

Definition of Stability for the Stellar Telescopic Crane Products:

A truck is stable until the load cannot be lifted off the ground with the winch, without tipping over the truck. Every Stellar crane installed must be tested for stability to determine the actual load capacity of the final truck package. The actual test data must be recorded and supplied with the truck at the time of in-service and should be kept with the truck at all times. The following procedure will test the truck package for stability and will provide a stability capacity chart. The load limit information shown on the stability capacity chart is formulated on 85% tipping.

Set Up:

1. Locate the truck on a test course in position for loading and engage travel brakes.

2. Set outriggers so that they make contact with firm, level footings.

3. Operate the crane under partial load to assure operator proficiency and proper

machine function.

6620 Stability Data

Max Horizontal Reach: 249” (From the center of rotation to boom tip) Stability Test Weight: 2150 lbs.

Test Procedure

1. Rotate the crane into Zone 1 position.

2. With the crane fully retracted and the boom horizontal, winch the test weight off the

ground. Note: Keep weight within six inches of the ground at all times.

3. Extend the boom outward until full extension has been reached or until the truck

becomes unstable (Again, use the winch to keep the weight within six inches of the ground.)

4. If the boom goes full extension without becoming unstable, the crane is termed stable

for this zone and 100% can be written in the Zone 1 data box.

5. If the truck becomes unstable prior to going full extension, retract the boom until the

truck becomes stable and measure the horizontal reach in this position (center of rotation to boom tip). This is the stable horizontal reach for this zone. Stable horizontal reach divided by Maximum horizontal reach multiplied by 100 equals the percentage of rated capacity for this zone. Use the following formula to determine the percentage of rated capacity:

6. Record this number in the data box for Zone 1. This is the revised capacity due to

stability for this zone.

7. Repeat this procedure for each zone until the worksheet is completed.

8. This is the revised capacity based on stability of this package.

Page 38

34 6620 Owner’s Manual

STABILITY CAPACITY CHART

Stability Capacity Chart

For a decal version of this capacity chart, please contact Stellar Customer Service at (800) 321-3741

Page 39

Assembly Drawings 35

GASKET SHOWN AS REFERENCE

.YTQ

OITPIRCSE

APMETI

1 11453 BEARING SWING DRIVE CAST BASE 6620 1

DILS 004 0283 POTS245

2 3C6069 MOTOR HYD ROSS MK080613AAAB 1

28RG TALF 05.0 REHSA

W0970

5D1307 CAP SCR 0.50-13X1.25 SH 2

1ENARC 0266 BTT DRAUG03721

6 713959 CAP SCR 1.00-8 X .63 PLASTIC 2

ALF

52.0 REH

SAW

9 0479 CAP SCR 0.25-20X0.75 HHGR5 2 10 21151 GASKET MOTOR 008-10056-1 1 11 D1345 FTG CPRSN 0.12NPT/0.25 TUBE 2 12 D1810 TBE AIR SAEJ844 TYPE A .25 (28") 1

1.0 EPIP REL

OC GTF6

522

C31

HGIARTS TPN 8/1 KREZ2951c4

P/N 17375

Chapter 7 - Assembly Drawings

Base Assembly - PN 17375

Page 40

36 6620 Owner’s Manual

5 1

0 1

7 1

3 1

1 1

6 1

2 1

9 1

. Y T Q N O I T P I R C S E D T R A

M E T

1 E N A R C

2 6

T S A M 7 1 5 9

4 1 8 R G W O L L E Y

T A L F

E A S 3 6 . 0 R E

H S A W

2 0 9 5 C 2

4 1 Y Z 8 R G H H 0 0 .

3 X

1 1 - 3 6 . 0 R C S P A

4 3 0 1 D 3

R G T A L F

8 3 . 0 R E H S

A W 3

5 3

6 C 4

4 8 R G H H 5 7 . 1 X 6 1 - 8 3 . 0

C S P A C 7

2 1 5

4 C O L Y N H H 6 1 - 8 3 . 0 T U N 7 4

3 0

M P G

8 G N I L R E T

S P O R P / W T C E L E T C E S 4

B V 5 8 6 4

G H

5 7 .

X 8

1 3 . 0

R C

A C

9 3

1 4

2 8

4 C N I Z T A L F S S U 1 3 . 0 R E H S A W 3 4 3 0 9 2 C O L Y N H H 8 1 - 1 3 . 0 T U N 2 4 3 0 0 1 1 T S A M 0 2 6 6 R E V O C 0 1 9 1 1 1

A L F 5 2 . 0 R E H S A W

4 3 0

4 5 R G H H 5 7 . 0 X 8 1 - 1 3 . 0 R C S P A C 0 2 4 0 3 1 1 # 0 0 0 3 S ' C I T A M E N I K H C N I W

6 3 1 1 4

W M

H U 8

3 . 0 X 5 7 . 0 X 8 3

. 0

R A L L O C 3 1 8 7

2 5 1

4 K C O L R A G 0 5 . 1 X 0 0 . 2 4 2 R X D 2 3 G N I H S U B 0 8 3 4 6 1 1 2 H N T C F 6 L O R T N O C O I D A R R E V I E C E R 3 0 1 4 3 7 1 2 5 R G

H H 0

5 .

1 X 0 2 - 5 2

. 0

R C S P A C 0

2 2 0

8 1

2 C O L Y N 5 R G H H 0 2 - 5 2 .

T U N 3 3 3 0 9 1

P/N 17376

Mast Assembly - PN 17376

Page 41

Assembly Drawings 37

. Y T

Q N

I T P

I R C S E

T R A P

M E

1 0 2 6 6 M

E N N I

E N

I 0 2 6 6 M S

A R

E D

N I L Y C

1 8 2

C O

L R

A G

. 2 X 0 0

. 2

R X

D 2 3

I H S

B 1

8 3

4 3

4 2 -

1 6 1

- I S

G N I H S U

B 8

0 4

& D 9 1 . 0 1

X 0 0 . 2 N I P 9 0 7 9 5

6 5

X 0 5 . 3 X 6 5 . 0 P A C N I

P 7 7

3 8 6

8 R G

T A

L F

0 5 . 0

R E H S A W 0 9 7

4 1

Y Z 8 R G

H H

0 0 .

1 X 3

1 - 0 5 . 0 R C S P A C

1 T & D

8 8 .

0 .

2 N I

P 1 1 7

9 9

1 T

6 . 1 1

X 0 0

N I P 0 1 7 9

. Y T Q N O I T P

I R C S E D T R A P M E

T I

T & D 8 3 . 8 X 0 0 . 1 N I

1 7 9 1

2 2 5 2 . X 0 5 . 2

X 4 4 . 0 P

C N I P 3 0 4 7 2 1

6 8

R G T A L F 8 3 . 0 R E H

S A

W 3

5 3 6 C 3

R G

H H 5 7 . 0 X 6 1 -

8 3 . 0

R C S P

4 8 9

R O T

A C I D N I E L G N A E T A L P 4 9 1 1 D

2 C O L

Y N 5 R G H H 3 1 - 0 5 . 0 T U N 6

0 1 6 C 6

O R T A L

Y N D N R 0 0

. 2 X 2 1 . 1 D

P R A E

W 3 6 3

R O

P U

S D

A P

R A E

W E T A L P 5 4 5 9 8 1

1 0 2 6

9 E

D I U G E P O R T K R

5 3 4

3 1

9 1

5 R G H H 0 0 . 9 X 6 1

- 8 3 . 0 R C S P A

8 6 1

2 1

0 2

8 1

4 1

3 1

2 1

3 1

2 1

0 2

5 1

5 2

4 2

7 2

8 2

Y T Q

N O I T P

I R

C S E D

T R

A P

M E T

2 W M

U 0 2 6 6 E

D I U G E

P O R

R E

C A P S 0 2

7 7

2 1 2

4 C O

L Y

H 6 1 - 8 3 . 0

U N 7 4 3 0 2 2

G H

H 5

2 .

1 X 6

- 8 3

C S P

C 5

0 3

Y N I V

K L B

5 2 . 0 P

M A

C 6

0 6 5

4 2

2 T

A L F

2 . 0

R E

H S

W 0 4 3 0 5 2

0 2

6 6 L E E R

D R

O C 4 4 5 1 1

6 2

5 R G H H

5 .

0 X 0 2 - 5 2 . 0 R C S P

C 8 7 4

G 0 1

I 5 2 . 1 R E

H S

W Y H

A M 5 2 4 0

8 2

P/N 17377

Main Boom - PN 17377

Page 42

38 6620 Owner’s Manual

OITPIRCSEDTRAPMETI

66 MOOB TXE64

10266 DN2 MOOB TXE

9459

3 37017 CYLINDER EXT ASM 6620 9985P 1

4 9991 WEAR PAD 0.25X2.00 RND NYLATRON 4

5 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 2

05.4X00.1 HCTIH NIP4282

1HCNYL 65.1X91.0 NIP357

8 9706 PIN TEAR DROP 1.00X3.25 2

9 0343 WASHER 0.31 USS FLAT ZINC 2

10 0484 CAP SCR 0.31-18 X 0.50 HHGR5 2

11 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 1

12 4974 CAP SCR 0.75-10X2.50 HHGR8 ZY 1

13 27719 SPACER BOOM TIP 6620 UHMW 2

14 12178 CAP SCR 0.31-18X3.25 HHGR5 2

COLYN HH 81-13.0 TUN243051

P 0914 NL PMALC ESOH733061

17 0220 CAP SCR 0.25-20 X 1.50 HHGR5 2

18 9363 WEAR PAD 1.12X2.00 RND NYLATRON 2

19 9545 PLATE WEAR PAD SUPPORT 2

8RG TALF 05.0 REHSAW0970D02

21 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 8

22 0425 MACHY WASHER 1.25ID 10GA 2

P/N 17378

Extension Boom Assembly - PN 17378

Page 43

Assembly Drawings 39

.YTQ

OITPIRCSEDTRAPMETI

10266 TS1 MOOB TXE

9374

234943 EXT BOOM 2ND 6620 FLIP SHEAVE 1

312929 PLATE SHEAVE MOUNTING 2

205.4X00.1 HCTIH NIP428214

HCNYL

65.1X91.0 NIP35

755

69363 WEAR PAD 1.12X2.00 RND NYLATRON 2

79545 PLATE WEAR PAD SUPPORT 2

88RG TALF 05.0 REHS

AW097

910172 CAP SCR 0.50-13X1.00 HHGR8 ZY 8

10 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 2

11 13400 PIN TEAR DROP 1.00X4.38 1

12 13399 PIN TEAR DROP 1.00X3.81 1

13 0343 WASHER 0.31 USS FLAT ZINC 2

14 0484 CAP SCR 0.31-18 X 0.50 HHGR5 2

15 9991 WEAR PAD 0.25X2.00 RND NYLATRON 4

16 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 1

17 4974 CAP SCR 0.75-10X2.50 HHGR8 ZY 1

18 27719 SPACER BOOM TIP 6620 UHMW 2

19 0490 CAP SCR 0.31-18X3.50 HHGR5 2

2COLYN HH 81-13.0 TUN243002

21 0425 MACHY WASHER 1.25ID 10GA 2

22 37017 CYLINDER EXT ASM 6620 9985P RELIEF 1

P/N 25428

Extension Boom Assembly (Flip Sheave) - PN 25428

Page 44

40 6620 Owner’s Manual

NEREFER SA NWO

S SGNIHSUB

.YTQNOITPIRCSEDTRAPMETI

183.12X00.4 0266 RENNI REDNILYC96691 4

-OLO5F-6 TPADA GTF97202 2

0266 LYC

NIAM 88.8X83.0 MSA EBUT85121

1GNIDLOH RENNI 0266 MSA DLOFINAM080314 4KCOLRAG 00.2X00.2 23RXD23 GNIHSUB18345

P/N 24281

Cylinder

Serial Tag

Location

Main Cylinder Assembly - PN 24281

Note: Main Cylinder uses

Stellar Seal Kit P/N 17724

Page 45

Assembly Drawings 41

YTQNOIT

PIRC

SED

APMETI 1 9985 CYLINDER EXT 6620 2 STAGE 1 2 14115 MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 1 311882 CAP SCR 0.38-16X1.75 SH ZC 2 414601 CAP SCR 0.38-16X2.25 SH ZC 1 5 14442 TUBE ASM 0.38X23.25 EXT CYL 6620 1 618701 CLAMP PORT TUBE ZR518 1 724729 HOSE CLAMP #52 3.00 - 3.75 1 8C4660 HOSE CLAMP 1SS 42# 936716 TUBE ASM 0.38X86.81 EXT CYL 1 10 26212 TUBE ASM 0.38X9.63 MAIN CYL 6620 1 11 C1854 FTG ADAPT 6-8 F5OLO-S 2 12 C2238 VALVE RELIEF 750PSI 49040-750 1

P/N 37017

Cylinder

Serial Tag

Location

Extension Cylinder Assembly - PN 37017

Note: Upper Extension

Cylinder uses Stellar Seal

Kit P/N 20450

Note: Lower Extension

Cylinder uses Stellar Seal

Kit P/N 20310

Page 46

42 6620 Owner’s Manual

.YTQNOITPIRCSE

TRAPMETI 1 11934 SHEAVE 6620 6.50 DIA .31R/1.12 THK 1 237120PC PLATE 6620 SNATCH BLOCK 2 327812 SPACER 6620 SNATCH BLOCK UHMW 2 4 11666PC SPACER 5520 SNATCH BLOCK 1 54975 CAP SCR 0.75-10X3.50 HHGR8 ZY 3 6 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 6 7 C0538 NUT 0.75-10 HHGR8 NYLOC 3 89610 WIRE ROPE 0.31 6X19 IWRC-XIP 90FT 1 99263 PIN .38X3.00 QUICK RELEASE 1

10 25831 HOOK 5 TON SWIVEL CROSBY 1028623 1 11 11938 SWITCH LIMIT A2B FURNAS 3SE3170 1 12 33749 SCREW #10-24X1.75 SHGR8 ZINC 4 13 34354 ANTI 2 BLOCK COVER LH 1 14 D1711 CAP SCR #10-24X0.50 BTNHD SS 1 15 C4956 NUT #10-24 HH NYLOC SS 1

171X501.0 NIAHC3548161 1KCOLB 2 ITNA THGIEWCP4625371

18 0530 CAP SCR 0.38-16X2.75 HHGR5 1

OLYN HH 61-83.0 TUN743091

1RETTOC 57.2X00.1 NIP1067302

21 0424 MACHY WASHER 1.00ID 10GA 2

200.1X521. NIP RETTOC

287322

23 37850 CONNECTOR QUICK LINK 0.13 1

P/N 38181

Cable & Hook Assembly - PN 38181

Page 47

Assembly Drawings 43

Wire Rope/Sheave Configurations

Page 48

44 6620 Owner’s Manual

Page 49

Hydraulics - Electrical 45

PN 10701

Chapter 8 - Hydraulics - Electrical

Control Kit - PN 10701

Page 50

46 6620 Owner’s Manual

P/N 38989

Control Kit (Power House 24) - PN 38989

Page 51

P/N 13042

Hydraulic Kit - PN 13042

47Hydraulics - Electrical 47

Page 52

48 6620 Owner’s Manual

C I T A M E H C S C I L U A

D Y

Y T Q N O I T P I R C S E D T R A

P M

E T I

1 0 9

/ 5 8

4 2

V L A V

F E

I L

E R 7

3 5

2 1

6 3 5 2 T I K

L A

E S 8 6 3 5 2

1 8

- 0 N 0 5 1 3 C 4 0 P J

/ P R P

L R T C W L F E V L

A V

0 6 9 4

2 2

8 3 5 2 /

0 6

9 4 2 T I K

L A

E S 9 6 3 5 2

1 7 5 4 0 G D N A T Y A W 4 S O P

3 D N

L O S E V L A V 1 7

3 5 2

1 1 9

4 0 G N E P O Y A W 4

O P

N L

S E V L A V

7 3 5 2

2 7 3 5 2 / 1 7 3 5 2

T I K

L A

E S

3 7 3 5 2

0 9 6

4 2 / 5 8 6 4 2 E

L A M

D R A K C A P C D V 2

1 L I O

C 0 7 3 5

Y T Q N O I T P I R C S E D T R A

P M

E T I

1 0 9

/ 5 8

4 2

V L A V

F E

I L

E R 7

3 5

2 1

6 3 5 2 T I K

L A

E S 8 6 3 5 2

1 8

- 0 N 0 5 1 3 C 4 0 P J

/ P R P

L R T C W L F E V L

A V

0 6 9 4

2 2

8 3 5 2 /

0 6

9 4 2 T I K

L A

E S 9 6 3 5 2

1 7 5 4 0 G D N A T Y A W 4 S O P

3 D N

L O S E V L A V 1 7

3 5 2

1 1 9

4 0 G N E P O Y A W 4

O P

N L

S E V L A V

7 3 5 2

2 7 3 5 2 / 1 7 3 5 2

T I K

L A

E S

3 7 3 5 2

0 9 6

4 2 / 5 8 6 4 2 E

L A M

D R A K C A P C D V 2

1 L I O

C 0 7 3 5

P/N 24685

Valve Identification

Valve Item #3 P/N 25371 GS0457 Valve Item #4 P/N 25378 GS0459

Valve Bank - PN 24685

Page 53

Hydraulic Installation

1. After mounting, locate the pressure and return lines. Note: Pressure line is 3/8” hose; Return line is 1/2” hose. Hoses are terminated using swivel fittings.

2. Install hydraulic lines per diagram below. Note: Outrigger valve supplies oil to crane using the Power Beyond feature.

3. Install hydraulic reservoir with return filter. Attach pump pressure line to valve, return link to tank.

4. Fill system with hydraulic oil (Mobil DTE13M is recommended).

49Hydraulics - Electrical 49

Page 54

50 6620 Owner’s Manual

Hydraulic System

Page 55

Chapter 9 - Replacement Parts

PART# DESCRIPTION SUGGESTED QTY

C6069 HYDRAULIC SWING MOTOR 1

31079 HYDRAULIC SWING MOTOR SEAL KIT 1 25367 RELIEF VALVE 1 25368 SEAL KIT - RELIEF VALVE 1 24960 FLOW CONTROL VALVE 1 25369 SEAL KIT - FLOW CONTROL VALVE 1 25371 SOLENOID VALVE TAND G04571 2 25372 SOLENOID VALVE OPEN G04591 1 25373 SEAL KIT - SOLENOID VALVE 2 25370 COIL - 12VDC 1 13080 MANIFOLD ASM - MAIN CYLINDER

9803 C-BALANCE VALVE 1 11991 PLUG - C-BALANCE 1 14115 MANIFOLD ASM - EXTENSION CYLINDER 1 14390 O'RING - MANIFOLD ASM EXT. CYLINDER 2

4587 PRESSURE SWITCH 1

6397 HYD PRESSURE GUAGE 1

C2027 O'RING - # 4 FACE SEAL 4 C2028 O'RING - # 6 FACE SEAL 4 C2029 O'RING - # 8 FACE SEAL 4 D1245 O'RING - # 4 SAE 4 D1246 O'RING - # 6 SAE 4 D1247 O'RING - # 8 SAE 4

17724 LIFT CYLINDER SEAL KIT 1 20310 EXT CYLINDER LOWER SEAL KIT 1 20450 EXT CYLINDER UPPER SEAL KIT 1 12158 TUBE ASM - MAIN CYLINDER 1 14442 TUBE ASM - EXTENSION CYLINDER 1 14443 TUBE ASM - EXTENSION CYLINDER 1

4380 BUSHING 2.00"x1.50" 2

4381 BUSHING 2.00"x2.00" 2

#0068 BUSHING 2

9363 WEAR PAD 1.12 X 2.00" ROUND 2

9991 WEAR PAD 2.50" ROUND 4

8377 PIN CAP .56 X 3.50 X .25 2

7403 PIN CAP .44 X 2.50 X .25 2

D0790 WASHER 0.50 FLAT GR8 4

10172 CAP SCR. 0.50-13 X 1.00" 4 11545 SHEAVE 1 11934 SHEAVE 1

9610 WIRE ROPE 1 12824 HITCH PIN 1.00" X 4.50" 1

9263 QUICK RELEASE PIN .38 X 3.00" 1 11938 LIMIT SWITCH 1 11544 CORD REEL 1 11835 RADIO REMOTE SYSTEM 1 20090 TRANSMITTER HANDLE / TRIGGER ASM 1 24958 TRIGGER ASM PROTECTION BOOT 1 22600 RADIO REMOTE TOGGLE SWITCH 2 16975 RADIO TRANSMITTER E-STOP SWITCH 1 12280 3.6V BATTERY 1

35264PC ANTI - 2 BLOCK WEIGHT 1

5753 LYNCH PIN 1 10710 5-TON HOOK LATCH ASM. 1

51Replacement Parts 51

Page 56

52 6620 Owner’s Manual

Page 57

Chapter 10 - Troubleshooting

53Troubleshooting 53

This chapter will list a number of potential problems that may occur while operating the crane. Most problems are easily solved using the solutions portion of this chapter. If problems persist, please contact Customer Service at Stellar Industries 1-800-321-3741.

Problem: Crane will not operate. Solutions:

• Make sure that the parking brake is engaged.

• Make sure that the PTO is engaged.

• Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter.

• Make sure that the transmitter batteries are fully charged. (Rechargeable batteries are good for 11 months or 200 charges)

• Make sure that the hydraulic pump is operating at its rated flow or GPMs. Check the flow by using the flow meter to determine the GPMs. It is possible that the hydraulic pump is getting weak. If this is suspected, contact Stellar Customer Service.

Problem: Crane will operate manually but will not operate electrically. Solutions:

• Make sure that the parking brake is engaged.

• Make sure that the parking brake switch is working properly. Check the parking brake switch by performing a continuity test. If the switch is defective, simply replace it.

Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently. Solutions:

• Make sure that the toggle switch is working properly. If the switch is defective, simply replace it.

• Make sure that there is power going from the valve bank coil solenoid or to the function that will not operate. If no power is going to the coil solenoid, check wiring connections on wire harness plug connector for broken wires, loose connection or poor crimp. If power is going to the solenoid valve, it may not be opening to allow hydraulic oil to the function that is not operating. Remove stem valve, thoroughly clean, lubricate, and reinstall valve. Do not over tighten. If the valve will not close, simply replace it.

Problem: Two functions operate at the same time while only toggling one function. Solutions:

• Make sure that the solenoid valves are all in the center position.

• Determine the function that is operating on its own. Check to see if there is power going to the solenoid valve from a function that should not be operating. If voltage is present at the solenoid valve without operating the function, the toggle switch has failed and is stuck in the “on” function. If no voltage is present, the solenoid valve may be partially open. Remove the stem valve, thoroughly clean, lubricate, and reinstall the valve. Do not over tighten. If valve will not close, simply replace it.

Problem: Winch brake will not hold. Solutions:

• Check to see if the back pressure on the return line of the winch is greater than 50 psi. Try operating a function other than the winch. Operate the function both ways and then stop. Now operate the winch. If the brake still does not hold, contact Customer Service at Stellar.

Page 58

54 6620 Owner’s Manual

Problem: Winch will not hold load. Solutions:

• Make sure that the object being lifted does not exceed the rated capacity of the winch. Refer to the capacity chart. If the object is within the rated capacity, reposition the truck and try to lift the object without using the crane boom extensions.

• Make sure that the relief valve on the winch is set correctly. Readjust the relief valve if necessary.

Problem: Crane only operates at full speed. Solutions:

• Check to see if there is 12V power constantly going to the proportional valve. If 12 volts are showing up at the proportional valve without pulling on the transmitter trigger, the handle/trigger assembly may be defective. If 8 volts are showing at the proportional valve, it is possible that the valve is stuck open and will not close. Remove the valve, clean it thoroughly and reinstall. Do not over tighten. If the problem persists, replace the proportional valve.

• Check to see if the manual override on the proportional valve is turned out. Turn the manual override on the flow valve in.

Problem: Crane operates slowly. Solutions:

• Make sure that the crane is receiving the recommended GPMs to operate.

• Check the level of hydraulic fluid in the reservoir. Add fluid as needed.

• Check to see if the valve bank orifice is plugged. If so, replace the orifice. Call Stellar Customer Service for instructions.

• Make sure the proportional valve is receiving 12V power when fully engaging the transmitter trigger. If there is not 12V power while pulling the trigger, check for loose connections inside the transmitter or replace the handle trigger assembly. If the proportional valve is receiving 12 volts, loosen the solenoid holding nut and check to see if the solenoid coil is magnetizing. If no polarity is present, replace the coil. If coil is magnetizing, remove the stem valve, thoroughly clean, lubricate, and reinstall the valve.

Problem: Winch “Up”, Main Cylinder “Down”, and Extension Cylinder “Out” are the only functions that don’t operate. Solutions:

• Make sure that the unit 2-block weight and chain on the end of the boom are straight so they slide easily along the wire rope cable.

• Make sure that the limit switch is working properly. Disconnect the two wires connected to the limit switch and tie them together. If all functions operate, replace the limit switch.

• Make sure that the cord for the cord reel is undamaged. Check the continuity of the cord. Disconnect the cord reel from the crane harness and bypass the harness connection. If the crane operates properly, replace cord reel.

Problem: Cylinder drifts outward or downward. Solutions:

• Check to see if there is air in the hydraulic system. Operate all cylinders connected to the hydraulic system. Start with the extension cylinder, then operate the main boom, winch, rotation, and ending with the hydraulic outriggers, if installed. When operating, extend each cylinder halfway out, retract all the way in, and then extend until the cylinder rod is at the end of its stroke. Operate cylinders slowly so air is pushed thru the system to the reservoir. Repeat this cycle 2-3 times.

• Make sure the holding valves are operating properly. Remove, clean, and then inspect each holding valve. When removing a holding valve, always relieve the pressure inside the cylinder by loosening jam nut of the holding valve and turning set screw inward/clockwise. Count the number of turns until the set screw is seated. When reinstalling the holding valve, make sure the valve is reset by turning the set screw the number of turns it took to relieve the pressure. Finish by tightening the jam nut.

• Check the cylinder rod for scratches. If a scratch is located on the cylinder rod, hydraulic fluid can pass thru and cause a loss of pressure. Replace cylinder rod or cylinder.

• Check to see if the piston seals are damaged. If they show signs of damage, install a new cylinder seal kit.

Page 59

6 Function Hetronic Radio Remote Troubleshooting

If the system does not operate after normal start-up, follow the recommended

troubleshooting sequence to help isolate the cause and determine corrective action.

55Troubleshooting 55

Transmitter

• Is the E-Stop pushbutton pulled out?

• Are all the switches in their center (neutral) position.

• Are the batteries in the transmitter fully charged?

• Is the transmitter inside its operating range?

PROBLEM

System will not operate after normal start-up procedure.

Transmitter is transmitting (Power LED flashing), but crane will not respond

PROBABLE CAUSE

E-Stop switch engaged

Batteries fully discharged

No power to the receiver

E-Stop switch engaged

Transmitter out of range

Receiver

• Is the antenna plug securely connected?

• If there is an external antenna, is the antenna connection assembly outside the enclosure secure?

• Are the power supply and ground wires securely fastened?

• Are the signal wires separated from the power supply wires?

CORRECTION

Pull out E-Stop switch.

Check batteries to ensure a full charge. Replace with new batteries if necessary.

Check the diagnostic LED on the receiver to be sure power is applied. Ensure that the system is properly grounded.

Pull out the E-Stop push button and activated switch on transmitter.

Take the transmitter back into the range of the receiver.

All crane motions operate intermittently

Some crane motions operate intermittently

Receiver power off

E-Stop failure in transmitter

Receiver antenna is loose or missing

External antenna (if used) has loose connection, poor grounding or interference

Ground wiring is poor. Conductor is too small, or receiver is grounded to chassis.

Crane motion wiring may be loose.

Turn on power to receiver.

Check E-Stop pushbutton for damage. Check wiring to contact element for broken or disconnected wires. Repair or replace E-Stop push button or wiring.

Tighten or replace antenna.

Tighten antenna and ground connection.

Ground wiring must be connected to machine power source ground. Minimum diameter of conductor ground is 12 AWG.

Check wiring from receiver to plug and from plug to crane motion actuator.

Page 60

56 6620 Owner’s Manual

Transmitter Troubleshooting

Notice: When testing the transmitter, the receiver may become active resulting in system operation. Always assume the system is working and will respond when testing a transmitter.

Status LED Troubleshooting

LED Indication

LED is off LED flashes LED will not light when any button is pushed, or LED remains on continuously

Transmitter is off Transmitter is operating in a normal mode Replace batteries. If this does not correct the problem, the transmitter must be returned for repair.

Transmitter Repairs

Notice: The transmitter electronic components are exposed when the back of the case is removed. Take caution to prevent dirt or other contaminants from entering the case. Do not allow the circuit to be scraped or damaged in any way.

Possible Cause

Receiver Troubleshooting

The following steps should be followed when troubleshooting the receiver.

1. Check the LED indicator. If it is not lit: a. Make sure 12 VDC and ground is present at the connecting wires. b. If using the AC power, check for AC power on the connecting wires. c. If input power is present and the LED is off, check the fuse inside the receiver case. d. If input power is present and the LED is off, and the fuse inside the receiver case is OK, contact Customer

Service at Stellar Industries.

2. Activate the transmitter by pressing any command switch. a. If the receiver LED does not flash, test the transmitter. b. Verify the identity code is the same for the transmitter and receiver. use the learn button to re-program the

receiver for the transmitter.

c. Contact Customer Service at Stellar Industries.

3. Only some functions are operating: a. Check to make sure the common wires for the relays are connected properly. (See Installation drawings for

details. b. Check output voltage of the respective wires and the electrical circuits. c. Check the fuses inside the receiver case. d. Check the receiver label to verify the function has been programmed to the needs of the equipment.

4. You are experiencing intermittent operation: a. Check antenna connections and antenna location. b. On AC systems, ensure noise suppression devices have been placed across the coils of all contacts. c. Ensure you are inside the operating range of the receiver and have line of sight to the receiver antenna.

5. Operating Range is short: a. Check all antenna connections and transmitter operation. b. On new installations, verify the receiver antenna is placed properly. If necessary, use an antenna mounting

kit to relocate the antenna to a more favorable location.

Receiver Testing

LED Indication

LED on continuous

LED flashes

LED goes off

Receiver Action

Receiver operating voltage is present, no signal is being received. Signal is being received that matches the decoders address. Signal is being received, but address is wrong.

Page 61

4 & 7 Function Hetronic Radio Remote Troubleshooting

Problem: Transmitter will not communicate with the Receiver.

(Note: Make sure the PTO is fully engaged when troubleshooting the problem.)

1. Is the main power switch on? (Control panel located inside the cab.)

2. Is the emergency brake engaged?

3. Is the transmitter battery fully charged? (Note: When the battery is fully charged, there should be a quick beep sound from the transmitter when toggling a function. A longer or constant steady beep indicates that the battery charge is weak or going dead.)

4. Is the E-Stop switch button pulled out or engaged?

Check the receiver functions.

(Note: Remove the receiver cover located on the crane mast) With the main power on, check the following functions:

1. Is the yellow light flashing in the upper left hand corner of the receiver?

a. Yes –

i. Check the signal functions using the transmitter toggle functions - go to step 2.

b. No –

i. Check the 7.5 fuse located inside the receiver. Replace the fuse if it has blown. ii. If the 7.5 fuse is ok, check the crane power fuse. (Usually located under the chassis hood

near the 300 amp continuous duty solenoid.)

57Troubleshooting 57

2. Does the green light in the upper left hand corner of the receiver flash when operating a toggle switch on the transmitter?

a. Yes –

i. Go to step 3.

b. No –

i. Carefully remove the switch face plate housing from the transmitter and check the

following areas:

1. Check to see if a jumper spade, from the CS458 TX-RF module, is loose or laying inside the transmitter, either laying on, or beneath the coder board.

2. Check for broken wires on the CS458 TX-RF Module. (Blue, Red, and White with blue stripes - Three wires total.

3. Check to make sure that the E-Stop 2 Wire connector plug (Located in the upper right hand corner of the coder board) isn’t loose or disconnected. (Usually a grey and white with brown stripe wire.)

4. Check for loose, corroded, or broken wires on the toggle switches. Note: If the green light inside the receiver flashed constantly without engaging a toggle switch, the coder board has failed or a toggle switch may be weak or broken.

3. Are the red LED function lights coming on when activating a toggle on the transmitter?

a. Yes –

i. Go to Step 4.

b. No –

i. The E-Stop switch or coder board has failed.

4. All lights are working properly?

a. Note: Radio system is functioning correctly - check the following areas:

i. Check for loose ground wires. ii. Check for loose or broken wires on the crane valve bank wiring harness. iii. Check to make sure the flow control valve on the valve bank is actuating properly, using

the trigger assembly of the transmitter.

iv. Check the anti-2-blocking electrical circuit (Limit switch, cord reel, and pressure switch - if

applicable) for proper operation.

b. If problem cannot be determined, contact customer service at Stellar Industries.

Page 62

Limited Warranty Statement

®®

Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following:

Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture, Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of manufacture, and Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts from the date recorded by Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.

The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the factory ship date will be used.

Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.

Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of the warranty claim.

Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service provider.

All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellarmanufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in writing, by Stellar.

The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.

The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.

All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.

Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured.

This warranty will apply to all Stellar Hooklifts, Stellar Service Trucks, & Truck-mounted Cranes shipped from Stellar’s factory after July 1, 2005. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Revision Date: February 2007 Document Number: 37040